Self-adhering joints for wood substrate flooring

ABSTRACT

An improved wood or engineered wood substrate panel, with one edge of each panel forming a first joint element and the opposing edge forming a complementary second joint element, wherein the first joint element from one panel is configured to mate and form a joint with the second joint element on an adjacent panel. Each panel is provided with complementary sealants or adhesives pre-installed on each joint element, so that the first joint element is joined with the second joint element to form the joint, an adhesive bond is automatically formed by the sealants on contact, or shortly thereafter, and no adhesive need be applied during installation.

This application claims priority to and benefit of U.S. Provisional Application No. 62/579,187, filed Oct. 31, 2017, which is incorporated herein by specific reference for all purposes.

FIELD OF INVENTION

This invention relates to a system of providing self-adhering joints for adjoining panels for a wood or engineered wood substrate, including wood substrate flooring panels.

BACKGROUND OF THE INVENTION

Adjacent wood panels forming a substrate often are joined by tongue-and-groove joints along abutting edges. However, when the substrate is intended to receive varying weight pressures, such as when used for flooring, the wood panels often are subject to substantial noise formation after installation. These noises often originate from movement of the panels at the tongue-and-groove joints, or from movement of the panels relative to supporting joists. While glue is recommended to be applied during installation (e.g., gluing the panels to the joints or to each other along the joints), in practice, gluing is often skipped, or the glue is inadequately or only partially applied.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a view of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In various exemplary embodiments, the present invention comprises an improved wood (including engineered wood) substrate panel, with one side/edge of each panel comprising a first joint element 10 and the opposing side of the panel comprising a second joint element 20, wherein the first joint element 10 from one panel 2 a is configured to mate and form a joint with the second joint element 20 on an adjacent panel 2 b. In one exemplary embodiment, the first joint element is a tongue, and the second joint element is a groove, together forming a tongue-and-groove joint, as seen in FIG. 1.

In one exemplary embodiment, each panel is provided pre-installation with a first edge sealant or seal 12 (e.g., adhesive) on the first joint element 10, and a second edge sealant or seal 22 (e.g., adhesive) on the second joint element 20. The first edge seal 12 and second edge seal 22 may be the same or different. One or both of the edge seals contain an additive or component so that when the first edge seal is mated together with the second edge seal (i.e., when the first joint element is joined with the second joint element to form the joint), an adhesive bond is automatically formed, and no adhesive need be applied during installation (as required by prior art methods). In one exemplary embodiment, one edge sealant comprises epoxy, while the other edge sealant comprises a curing agent.

In an alternative embodiment, the formation of the adhesive bond may be initiated or facilitated with the introduction or application of a catalyst, such as water, being applied on one edge, with an MDI (methylene diphenyl diisocyanate) or other form of isocyanate or similar material pre-applied to the other edge.

In one embodiment, the invention comprises a high strength pressure sensitive adhesive applied as a first edge seal, second edge seal, or both, and covered with a release liner. The release liner or liners provide protection during storage and shipment and prevent exposure, premature curing, and/or health or safety issues. The release liners or liners are removed prior to installation, and may also be used with various combinations of sealants as described above (e.g., epoxy/curing agent).

The formation of the adhesive bond need not be immediate, but can form and strengthen over time, preventing accidental adhesion of panels, and allowing installers time to manipulate and place panels appropriately.

Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art. 

What is claimed is:
 1. An improved flooring system, comprising: a first flooring panel with a first edge and a second edge, the first edge comprising a first joint element, and the second edge comprising a second joint element; a second flooring panel with a first edge and a second edge, the first edge comprising a first joint element, and the second edge comprising a second joint element; wherein the first joint element of one of said panels is configured to mate with the second joint element of the other of said panels to form a joint between said panels when placed adjacent to one another; further wherein the respective first joint element is covered, at least in part, with a first sealant.
 2. The system of claim 1, wherein the respective second joint element is covered, at least in part, with a second sealant.
 3. The system of claim 2, wherein the first sealant and second sealant are operative to form an adhesive bond when placed in contact.
 4. The system of claim 3, further comprising a first liner covering the first sealant, and a second liner covering the second sealant.
 5. The system of claim 1, wherein the first joint element is a tongue, and the second joint element is a groove.
 6. The system of claim 1, wherein the panels comprise engineered wood.
 7. The system of claim 1, further comprising a first liner covering the first sealant.
 8. A flooring substrate, comprising: a panel with a first edge and a second edge, the first edge comprising a first joint element, and the second edge comprising a second joint element, wherein the first joint element in one half of a joint and the second joint element is the other half of the joint; further wherein the respective first joint element is covered, at least in part, with a first sealant.
 9. The substrate of claim 8, wherein the respective second joint element is covered, at least in part, with a second sealant.
 10. The substrate of claim 9, wherein the first sealant and second sealant are operative to form an adhesive bond if placed in contact.
 11. The system of claim 10, further comprising a first liner covering the first sealant, and a second liner covering the second sealant. 